Foam filling member

ABSTRACT

A foam filling member having a foaming base material in sheet form which is simplified in structure so that it can be formed into a predetermined shape corresponding to a shape of a space of a structure with an improved working efficiency and can also be placed in a space of the structure with an improved working efficiency, without any need of the sticking to a wall surface of a partition wall defining the space of the structure. Incisions  4, 5, 6, 7,  cut in partway along a thickness direction of the foaming base material  2  along a bending portion and cuts  9, 10  passing through in the thickness direction are formed in the foaming base material  2.  By simply bending or folding the foaming base material  2  along the incisions  4, 5, 6, 7  and the cuts  9, 10,  the foam filling member  1  can be formed in a three-dimensional shape corresponding to an interior space of a pillar and thus can be set in place in the interior space. By foaming the foaming base material  2  thus placed in the interior space, the foam can be filled up in the interior space, leaving no space therein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a foam filling member used for fillinga space of a structure with foam.

2. Description of the Prior Art

A foam filling member used for filling foaming material in a hollowstructure, such as a pillar of a vehicle, is generally known.

For example JP Laid-open (Unexamined) Patent Publication No. 2003-146243proposes a foam filling tool as an example of the foam filling member,which comprises a foaming base material formed of material which isfoamed by heating from outside, a supporting member having a supportingplate for supporting one side of the foaming base material, the foamingbase material being formed in generally annular form to correspond insize to the supporting plate, and an annular weir wall, projected fromone side of the supporting plate, for supporting an innercircumferential wall of the foaming base material.

According to this foam filling tool, when the foaming base material isheated from outside after the foam filling tool is set in place in ahollow room such as a pillar of a vehicle, the foam filling of thefoaming base material is suppressed with respect to a longitudinaldirection of the hollow room by the supporting plate and is acceleratedwith respect to a direction substantially orthogonal to the longitudinaldirection orienting toward the inner wall of the hollow room to producethe foam. Also, this foam filling of the foaming base material isprevented from progressing toward a center of an opening of the foamingbase material by the annular weir wall of the supporting plate. This canallow the effective and smooth filling of the hollow room with the foamproduced using a very small quantity of foaming base material to befoamed by heating.

Also, for example JP Laid-open (Unexamined) Patent Publication No.2003-94475 proposes a gap filling material in sheet form as an exampleof the foam filling member having an expanding layer of material to beexpanded by heating, one side of which grooves extending from one end tothe other are formed, and the other side of which a sticking layer isformed.

This gap filling material has reduced thicknesses at portions thereof atwhich the grooves are formed, so that it is well curved around a curvedsurface of a pillar of a vehicle. Hence, even when the curved surface towhich the gap filling material is stuck has a high curvature, the gapfilling material can be stuck around it, leaving no space therebetween,so that when foamed and expanded by heating, it can be well filled inthe gap leaving no space therebetween.

In the foam filling tool described by JP Laid-open (Unexamined) PatentPublication No. 2003-146243 cited above, the supporting plate is formedof hard, synthetic resin material so that when the foaming base materialis foamed, the supporting plate can be prevented from being bent in adirection substantially orthogonal to a direction of its surfaceextending. by the pressure acting in the same direction or by its ownweight, in order to prevent the foam filling of the foaming basematerial in a longitudinal direction of the hollow room, the droopingunder its own weight in the longitudinal direction or the dropping ofthe same. This requires that the supporting plate be previously moldedin a specified shape corresponding to a shape of cross section of thehollow room, thus requiring a variety of molds for various shapes ofcross section of the hollow room.

On the other hand, the gap filling material described by JP Laid-open(Unexamined) Patent Publication No. 2003-94475 cited above is designedto stick the sticking layer on the curved surface of the pillar of thevehicle. Due to this, when the gap filling material is stuck on thecurved surface and then is coated with an antirust paint and,thereafter, the expansion layer is expanded by heating from outside tofill the hollow room, there causes the problem that a region of thecurved surface where the gap filling material was stuck is not coatedwith the antirust paint.

SUMMARY OF THE INVENTION

It is an object of the invention to provide a foam filling member havinga foaming base material in sheet form which is simplified in structureso that it can be formed into a predetermined shape corresponding to ashape of a structure with an improved working efficiency and can also beplaced in a space of the structure with an improved working efficiency,without any need of the sticking to a wall surface of a partition walldefining the space of the structure.

The present invention provides a novel foam filling member used forfilling a space of a structure by foaming it, the foam filling membercomprising a foaming base material in the form of a sheet of foamablematerial in which incisions cut in partway along a thickness directionof the foaming base material along a bending portion and/or cuts passingthrough in the thickness direction of the foaming base material areformed, wherein the foaming base material is formed so that it can beformed in a predetermined shape by bending it along the incisions and/orthe cuts.

According to this foam filling member, the foam filling member can beformed in a predetermined shape corresponding to a space of a structurewith improved working efficiency by a simple structure of simply bendingor folding the foaming base material in sheet form along the incisionsand/or the cuts. This can eliminate the need of the mold having a cavitycorresponding to the shape of the space of the structure, and as suchcan allow cost reduction.

Also, the foam filling member is placed in the space of the structure inthe state of its bent portions of the foaming base material and itsouter edges of the foaming base material being in point-contact with orline-contact with the inside wall defining the interior space of thestructure. This can allow the foaming base material to be formed tocorrespond in shape to the space and be placed in the space without anyneed to be stuck on a wall of the space, thus producing an improvedworking efficiency. Also, since the foaming base material is in thestate of being not stuck on the wall of the space, the wall of the spacecan be subjected to required treatments even after the placement of thefoam filling member.

In the foam filling member of the present invention, it is preferablethat the foaming base material has a thickness of 0.5-6.0 mm and aflexural modulus of 20-150 MPa.

When the foaming base material is formed to have a thickness and aflexural modulus which fall within the respective specific ranges, aresilience repellent) to force the foaming base material as was placedin the space in the bent state back into its original sheet form beforebent is produced. This resilience of the foaming base material bringsthe foam filling member placed in the space into press-contact with thewall of the space, to hold the foam filling member in a certain shape inthe space of the structure. This can produce the result that the foamfilling member in the space of the structure can be reliably held in theform corresponding to the space.

In the foam filling member of the present invention, it is preferablethat the incisions and/or the cuts are formed along a longitudinaldirection of the foaming base material.

This formation of the incisions and/or the cuts can allow the foamfilling member to be formed in a predetermined shape corresponding to ashape of cross section of the space of the structure taken along adirection substantially orthogonal to a longitudinal direction of thespace of the structure by bending or folding the foaming base materialalong the incisions and/or cuts in the direction orthogonal to thelongitudinal direction.

In the foam filling member of the present invention, it is preferablethat the incisions and/or the cuts are formed along a directionintersecting with a longitudinal direction of the foaming base material.

This formation of the incisions and/or the cuts can allow the foamfilling member to be formed in a predetermined shape corresponding to ashape of cross section of the space of the structure taken along thelongitudinal direction of the space of the structure by bending orfolding the foaming base material along the incisions and/or cuts in thelongitudinal direction.

In the foam filling member of the present invention, it is preferablethat the foaming base material is provided with a retaining portion forretention to the structure.

The provision of the retaining portion for the foaming base material canallow the fixture of the foam filling member to the structure byretaining the retaining portion to the structure. This can allow thefoam filling member to be fixed to the wall at the retaining portiononly, and as such can ensure the fixture of the foam filling member tothe structure, without negatively affecting subsequent treatments to thewall of the space.

In the foam filling member of the present invention, it is preferablethat the foam filling member is used for foam filling in a first spaceand a second space of the structure comprising the first space, thesecond space adjoining to the first space, and a communication hole forcommunicating therebetween, wherein the foaming base material comprisesan inserting portion, formed partway along a longitudinal directionthereof, to be inserted through the communication hole, a first spacefilling portion, formed on one lengthwise side thereof with respect tothe inserting portion, to be placed in the first space, and a secondspace filling portion, formed on the other lengthwise side thereof withrespect to the inserting portion, to be placed in the second space.

This formation can allow one of the first space filling portion and thesecond space filling portion to be placed in its corresponding first orsecond space and can allow the other space filling portion to be placedin the other space by inserting one of the first space filling portionand the second space filling portion of the foam filling member in thecommunication hole and passing the inserting portion through thecommunication hole. This can eliminate the need to place the spacefilling member in each of the first space and the second space, thusproviding improved working efficiency. In addition, since both spacescan be filled with a single space filling member, cost reduction can beachieved.

Also, the present invention provides a foam filling member used forfilling a space of a structure by foaming it, the foam filling membercomprising a foaming base material in the form of a sheet of foamablematerial in which a cutout portion passing through a thickness directionthereof is formed, wherein the foaming base material is formed so thatit can be formed in a predetermined shape by inserting a foaming basematerial in the cutout portion.

According to this foam filling member, the foaming base material iscombined with an identical or different foaming base material byinserting the identical or different foaming base material in the cutoutportion of the foaming base material in sheet form, whereby the foamingbase material is formed in a predetermined shape corresponding to theshape of the space of the structure. This can provide a simple structurefor allowing the foaming base material to be formed into a predeterminedshape corresponding to the shape of the space of the structure with animproved working efficiency. This can eliminate the need of the moldhaving a cavity corresponding to the shape of the space of the structureand the like, and as such can allow cost reduction.

This can also allow the foaming base material to be placed in the spaceof the structure in a predetermined shape corresponding to the shape ofthe structure without any need to be stuck on a wall of the space, thusproducing an improved working efficiency. Also, since the foaming basematerial is in the state of being not stuck on the wall of the space,the wall of the space can be subjected to required treatments even afterthe placement of the foam filling member.

DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a plane view showing an embodiment (an elbow type) of a foamfilling member of the present invention,

FIG. 2 is an enlarged side view of one lengthwise short side of the foamfilling member shown in FIG. 1,

FIG. 3 is an enlarged side view of one widthwise long side of the foamfilling member shown in FIG. 1,

FIG. 4 is a perspective view showing the state of the foam fillingmember shown in FIG. 1 being bent along incisions and cuts to be formedin three dimension,

FIG. 5 is a sectional view showing the state of the foam filling memberof FIG. 4 formed in three dimension being placed in an interior space ofa pillar,

FIG. 6 is a plane view showing another embodiment (a ring-shaped type)of the foam filling member of the present invention,

FIG. 7 is an enlarged plane view showing a retaining portion of the foamfilling member of FIG. 6,

FIG. 8 is a sectional view showing the state of the foam filling membershown in FIG. 6 being bent along incisions and cuts to be formed inthree dimension and placed in the interior space of the pillar,

FIG. 9 is a longitudinal sectional view showing the state of theretaining portion of the foam filling member of FIG. 6 being inserted ina retaining hole of the pillar,

FIG. 10 is a cross-sectional view showing the state of the insertion ofthe retaining portion being completed from the state shown in FIG. 9,

FIG. 11 is a plane view showing still another embodiment (a figure-eightshape as viewed from side elevation) of the foam filling member of thepresent invention,

FIG. 12 is a sectional view showing the state of the foam filling memberof FIG. 11 being bent along incisions to be formed in three dimensionand placed in the interior space of the pillar,

FIG. 13 is a plane view showing a yet another embodiment (combination oftwo or more foam base materials) of the foam filling member of thepresent invention, and

FIG. 14 is a sectional view showing the state of the foam filling memberof FIG. 13 being formed in three dimension and placed in the interiorspace of the pillar.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a plane view showing an embodiment of a foam filling member ofthe present invention. FIG. 2 is an enlarged side view of one lengthwiseshort side of the foam filling member shown in FIG. 1. FIG. 3 is anenlarged side view of one widthwise long side of the foam filling membershown in FIG. 1.

A foam filling member 1 shown in FIG. 1 is used for filling foamingmaterial in an interior space 24, such as a pillar 21 of a vehicle asmentioned later and is formed by a single layer of foaming base material2 in sheet form of foamable material (Cf. FIG. 5).

The foaming base material 2 is formed of foaming material which isfoamed by heating (e.g. at about 120° C. to about 210° C.).

A known foamable polymer is used as the foamable material without anyparticular limitation. The foamable polymers that may be used include,for example, resins, such as ethylene•vinyl acetate copolymer,polyethylene, polypropylene, polyester, polyvinyl butyral, polyvinylchloride, polyamide, and polyketone, and rubbers, such asstyrene•butadiene rubber (SBR), and polybutadiene rubber (BR).Preferably, ethylene•vinyl acetate copolymer is used as the foamablematerial. The use of ethylene•vinyl acetate copolymer can provide anincreased foam ratio. At least one or two materials of foamable polymercan be properly selected from these foamable polymers.

For enhancement of the foaming and curing of the foamable polymer, forexample a cross-linking agent, a foaming agent, and, if necessary, afoam auxiliary agent, may be mixed further in the foamable material.

No particular limitation is imposed on the cross-linking agent, whilefor example a known radical forming agent that can be dissolved byheating to produce a free radical so as to form a cross-linking bondamong molecules or in an individual molecule is used as thecross-linking agent. To be more specific, the radical forming agentsthat may be used include, for example, organic peroxides, such asdicumyl peroxide, 1,1-ditertiarybutylperoxy-3,3,5-trimethylcyclohexane,2,5-dimethyl-2,5-ditertiarybutylperoxyhexane,2,5-dimethyl-2,5-ditertiarybutylperoxyhexyne,1,3-bis(tertiarybutylperoxyisopropyl)benzene, tertiarybutylperoxyketone,and tertiarybutylperoxybenzoate.

When the foamable polymer is to be vulcanized, a known vulcanizing agentcan be used as the cross-linking agent. No particular limitation isimposed on such a vulcanizing agent. For example, sulfur, sulfurcompounds, selenium, magnesium oxide, lead oxide, zinc oxide,polyamines, oximes, nitroso compounds, resins, and ammonium salts can becited as the vulcanizing agent.

At least one or two materials of these cross-linking agents can beselectively used. No particular limitation is imposed on a mixing ratioof the cross-linking agent. For example, a mixing ratio of thecross-linking agent to the foamable polymer is in the range of 0.1-10parts by weight, or preferably in the range of 0.5-7 parts by weight.

When the vulcanizing agent is used, a vulcanization accelerator may beused in combination. Known vulcanization accelerators including, forexample, dithiocarbamine acids, thiazoles, guanidines, sulfenamides,thiurams, xanthogen acids, aldehyde ammonias, aldehyde amines, andthioureas, may be used. At least one or two materials of thesevulcanization accelerators may be selectively used. A mixing ratio ofthe vulcanization accelerator to the foamable polymer is in the range of0.1-5 parts by weight.

On the other hand, rather than the vulcanization accelerators, knownvulcanization retardants such as, for example, organic acids and amines,may be properly selected for the mixture, for the purpose of moldingcontrol.

Also, no particular limitation is imposed on the foaming agent. Forexample, known inorganic or organic foaming agents are used. Theinorganic foaming agents that may be used include, for example, ammoniumcarbonate, ammonium hydrogen carbonate, sodium hydrogen carbonate,ammonium nitrite, sodium borohydride, and azides.

The organic foaming agents that may be used include, for example, azocompounds, such as azodicarbonamide, barium azodicarboxylate,azobisisobutyronitrile, and azodicarboxylic amide, nitroso compounds,such as N,N′-dinitrosopentamethylenetetramine,N,N′-dimethyl-N,N′-dinitrosoterephthalamide, andtrinitrotrimethyltriamine, hydrazide compounds, such as4,4′-oxybis(benzenesulfonylhydrazide), paratoluene sulfonylhydrazide,diphenylsulfone-3,3′-disulfonylhydrazide, andallylbis(sulfonylhydrazide), semicarbazide compounds, such asp-toluilene sulfonylsemicarbazide, and4,4′-oxybis(benzenesulfonylsemicarbazide), alkane fluorides, such astrichloromonofluoromethane, and dichloromonofluoromethane, and triazolecompounds, such as 5-morpholyl-1,2,3,4-thiatriazole.

Among these foaming agents, the one that is dissolved at a temperatureequal to or higher than a softening temperature of foamable polymer togenerate gas and is hardly foamed in the process of forming the foamingbase material 2 is selected properly in accordance to the compositionthereof. The foaming agent that is foamed in a temperature range betweenabout 120° C. and about 210° C. is preferably used.

At least one or two materials of these foaming agents can be selectivelyused. No particular limitation is imposed on a mixing ratio of thefoaming agent. For example, a mixing ratio of the foaming agent to thefoamable polymer is in the range of 5-50 parts by weight, or preferablyin the range of 10-30 parts by weight, per 100 parts by weight offoamable polymer.

A quantity of foaming agent mixed is preferably in such a range that thefoaming base material 2 containing the foaming agent, when foamed,practically generates a closed cell at about five to about twenty-fivetimes, or preferably about ten to about twenty times, the foam ratiothat the foaming base material containing no foaming agent does. When anexcessively small quantity of foaming agent is mixed, the foaming basematerial 2 is not foamed sufficiently, while on the other hand, when anexcessively large quantity of foaming agent is mixed, a resin drip ofthe foaming material obtained by the foaming is caused to therebyproduce a void in the foamed resin, both causing filling loss.

No particular limitation is imposed on the foam auxiliary agent. Forexample, a known foam auxiliary agent may be selected properly inaccordance to the type of foaming agent used. To be more specific, forexample, urea compounds containing urea as a main component, metaloxides, such as zinc oxide, and lead oxide, higher fatty acids, such assalicylic acid, and stearic acid, or metal salts thereof can be cited asthe foam auxiliary agent. A metal salt of a higher fatty acid ispreferably used.

At least one or two materials of these foam auxiliary agents can beselectively used. No particular limitation is imposed on a mixing ratioof the foam auxiliary agent. For example, a mixing ratio of the foamauxiliary agent to the foamable polymer is in the range of 1-20 parts byweight, or preferably in the range of 5-10 parts by weight, per 100parts by weight of foamable polymer.

Further, known additives including, for example, stabilizer, stiffener,filler, and softener and, if required, for example, plasticizer, ageresister, antioxidant, pigment, colorant, fungicide, and flameretardant, may be additionally mixed properly for intended purposes andapplications, within the range of having little influence on thephysicality of the foam obtained.

The foaming base material 2 is integrally formed in a rectangularplate-like shape as viewed from top. It has incisions 4, 5, 6, 7 formedin a surface 3 on one side thereof, which are cut partway along athickness direction thereof, as shown in FIG. 2, and also has cuts 9, 10passing completely through to a surface 8 on the other side in thethickness direction, as shown in FIG. 3. In FIG. 1, in order to makediscrimination between the incisions 4, 5, 6, 7 and the cuts 9, 10, theincisions 4, 5, 6, 7 are depicted in a broken line, and the cuts 9, 10are depicted in a solid line, for descriptive purposes.

A plurality of incisions 4 (four incisions) are formed linearly in thesurface 3 on one side of the foaming base material 2 to extend from oneshort side surface 11 on one longitudinal side thereof to the cuts 9, 10on the one side formed partway along the longitudinal direction of thefoaming base material 2 along the longitudinal direction of the foamingbase material 2. These incisions 4 are arranged in parallel with eachother at predetermined spaced intervals along a widthwise directionwhich is a direction orthogonal to the longitudinal direction of thefoaming base material 2. These four incisions 4 are equally spaced alongthe widthwise direction of the foaming base material, to take five equalparts of the foaming base material 2.

The incisions 4 are cut partway along the thickness direction of thefoaming base material 2 from the surface 3 on the one side toward thesurface 8 on the other side, as shown in FIG. 2. A cut-in depth A is0.1-0.9 times, or preferably 0.2-0.5 times, as long as a thickness B ofthe foaming base material 2.

Also, a cutting width is equal to a width of a cutter and is for example300 μm or less, preferably in the range of 10-100 μm.

A plurality of incisions 5 (four incisions) are formed linearly in thesurface 3 on one side of the foaming base material 2 to extend from theother short side surface 12 on the other longitudinal side thereof tothe cuts 9, 10 on the other side formed partway along the longitudinaldirection of the foaming base material 2 along the longitudinaldirection of the foaming base material 2. These incisions 5 are arrangedin parallel with each other at predetermined spaced intervals along thewidthwise direction of the foaming base material 2. These four incisions5 are equally spaced along the widthwise direction of the foaming basematerial 2, to take five equal parts of the foaming base material 2. Thecut-in depth and cutting width of the incisions 5 are the same as thoseof the incisions 4.

A plurality of cuts (two cuts) 9 are formed linearly in the surface 3 onone side of the foaming base material 2 to extend from one long sidesurface 13 on one widthwise side thereof to the second incisions 4, 5from the one long side surface 13 along the widthwise direction of thefoaming base material 2. The cuts 9 are arranged in parallel with eachother at predetermined spaced intervals, extending partway along thelongitudinal direction of the foaming base material 2.

A plurality of cuts (two cuts) 10 are formed linearly in the surface 3on one side of the foaming base material 2 to extend from the other longside surface 14 on one widthwise side thereof to the second incisions 4,5 from the other long side surface 14 along the widthwise direction ofthe foaming base material 2. The cuts 10 are arranged in parallel witheach other at predetermined spaced intervals, extending partway alongthe longitudinal direction of the foaming base material 2.

The respective cuts 9, 10 are arranged to confront each other acrosspredetermined spaced intervals along the widthwise direction of thefoaming base material 2 (the spaced intervals defined between the secondcuts 4, 5 from the one long side surface 13 and the second cuts 4, 5from the other long side surface 14).

The incisions 6, 7 are formed linearly along the widthwise direction toconnect between the respective cuts 9, 10 arranged in lines to confronteach other, respectively. The cut-in depth and cutting width of theincisions 6, 7 are the same as those of the incisions 4.

As a result of this formation of the incisions 4, 5, 6, 7 and the cuts9, 10, a first linearly extending portion 15 extending along thelongitudinal direction of the foaming base material 2 is defined by theone short side surface 11, the incision 6, and the cuttings 9, 10 formedat both widthwise sides of the incision 6; a second linearly extendingportion 16 extending along the longitudinal direction of the foamingbase material 2 is defined by the other short side surface 12, theincision 7, and the cuttings 9, 10 formed at both widthwise sides of theincision 7; and a first bending portion 17 is defined by the incision 6,the cuttings 9, 10 formed at both widthwise sides of the incision 6, theincision 7, and the cuttings 9, 10 formed at both widthwise sides of theincision 7. In the first linearly extending portion 15, a plurality offirst bending strips 18 (five bending strips) defined by the one longside surface 13, the other long side surface 14, and the respectiveincisions 4 are arranged along the widthwise direction. In the secondlinearly extending portion 16, a plurality of second bending strips 19(five bending strips) defined by the one long side surface 13, the otherlong side surface 14, and the respective incisions 5 are arranged alongthe widthwise direction.

The first linearly extending portion 15 and the first bending portion 17are coupled to each other through the incision 6 so that they can bebent in the longitudinal direction of the foaming base material 2. Thesecond linearly extending portion 16 and the first bending portion 17are coupled to each other through the incision 7 so that they can bebent in the longitudinal direction of the foaming base material 2.

This can allow the foaming base material 2 to be bent along the cut-indirection of the incisions 4, 5 at the first linearly extending portion15 and the second linearly extending portion 16 in the directionsindicated by solid arrows of FIG. 2, so that the first bending strips 18and the second bending strips 19, adjoining to each other in thewidthwise direction of the foaming base material 2, can be bent atpredetermined angles relative to each other.

This can also allow the foaming base material 2 to be bent along theincisions 6, 7 in the directions indicated by solid arrows of FIG. 3,with the one side surface 3 outward, and the other side surface 8 inwardwith respect to the bending direction, at the boundaries between thefirst linearly extending portion 15 and the first bending portion 17 andbetween the second linearly extending portion 16 and the first bendingportion 17. As a result, the first linearly extending portion 15 and thefirst bending portion 17, and the second linearly extending portion 16and the first bending portion 17, adjoining to each other in thelongitudinal direction of the foaming base material 2, are bent atpredetermined angles relative to each other.

The foaming base material 2 is produced in the following processes, forexample. First, after the respective components cited above are mixed inthe foaming material at a mixing ratio mentioned above, the mixture iskneaded using a mixing roll, a pressure kneader, and the like. Then, theresulting material is continuously formed in sheet form by thecontinuous molding using a press, a calender roll, or the like or by theextrusion using e.g. an extruder. Sequentially, the resulting sheet isstamped to form rectangular foaming base materials 2 and form theincisions 4, 5, 6, 7 and the cuts 9, 10 in the one side surfaces 3 ofthe respective foaming base materials 2. The foaming base materials 2can be produced in the processes mentioned above.

The foaming base materials 2 thus formed each have a thickness in therange of 0.5-6.0 mm, or preferable 1.5-3.5 mm, and also have a flexuralmodulus of elasticity in the range of 20-150 MPa, or preferably 60-100MPa. By setting the thickness and the flexural modulus of elasticity ofthe foaming base material 2 within those ranges, adequate degree offlexibility and repellent are given to the foaming base material 2.

The foaming base material 2 is bent along the incisions 4, 5, 6, 7 in adirection orthogonal to the cut-in direction of the incisions, with theone side surface 3 outward, and the other side surface 8 inward withrespect to the bending direction. As a result, the foaming base material2 is formed in a three-dimensional configuration corresponding to anelbow shape shown in FIG. 4.

Specifically, the five first bending strips 18 of the first linearlyextending portion 15 are bent along the four incisions 4 connectingbetween the first bending strips 18 in the direction orthogonal to thecut-in direction of the incisions, with the one side surface 3 outward,and the other side surface 8 inward with respect to the bendingdirection. As a result, the foaming base material 2 is formed to have,at the first linearly extending portion 15, an inverted U-shaped sectionas viewed from the widthwise direction.

Also, the five second bending strips 19 of the second linearly extendingportion 16 are bent along the four incisions 5 connecting between thesecond bending strips 19 in the direction orthogonal to the cut-indirection of the incisions, with the one side surface 3 outward, and theother side surface 8 inward with respect to the bending direction. As aresult, the foaming base material 2 is formed to have, at the secondlinearly extending portion 16, an inverted U-shaped section as viewedfrom the widthwise direction.

In addition, the first linearly extending portion 15 and the firstbending portion 17 are bent along the cut-in direction of the incision 6connecting therebetween, to bend in the direction orthogonal to thecut-in direction, and the second linearly extending portion 16 and thefirst bending portion 17 are bent along the cut-in direction of theincision 7 connecting therebetween, to bend in the direction orthogonalto the cut-in direction. Further, the first bending portion 17 is curvedto cover the one side surface 3 of the first and second linearlyextending portions 15, 16 as bent in the inverted U-shape in section. Asa result, the foaming base material 2 is formed in a generally invertedV-shape, when viewed from side elevation, with the one side surface 3outward, and the other side surface 8 inward with respect to the bendingdirection.

The foam filling member 1 thus produced is disposed in a space definedbetween structures or in an interior space of a hollow structure andthen is heated to a foaming temperature (e.g. about 120° C. to about210° C.). Then, the foam filling member 1 is foamed and thereby thespace is filled up, without leaving any space therein. Therefore, thisfoam filling member 1 can be used as foam filling members of a varietyof industrial fields, including, for example, vibration-proof material,soundproof insulator, dust-proof material, heat-proof material,cushioning material, and water-proof material, for the purposes ofdamping, noise reduction, dust control, heat insulation,shock-absorbing, and water tight, without being limited to anyparticular ones.

To be more specific, when this foam filling member 1 is used for fillinga hollow structure such as, for example, an interior space of a pillarof a vehicle by foaming, vibrations and noises of a vehicle engine orhissing sounds or fluttering sounds of the vehicle can be effectivelyprevented from being transmitted to the vehicle interior by the foamproduced by foaming.

Next, a method of filling up the interior space of the pillar of thevehicle will be explained, taking an example of use of this foam fillingmember 1.

In this method, the foam filling member 1 formed to correspond in shapeand size to a three-dimensional configuration of the interior space 24of the pillar 21 to be filled is set in the pillar 21, first, as shownin FIG. 5.

The pillar 21 is formed in a generally inverted V-shape (an elbow shape)having a bend pipe portion 20 bent partway along the longitudinaldirection and straight pipe portions 22, 23 formed integrally with thebend pipe portion 20 and extending straight from both lengthwise sidesof the bend pipe portion 20. One straight pipe portion 22 has, at oneend thereof opposite from the bend pipe portion 20, an opening 26 forreceiving the foam filling member 1 therefrom.

When the foam filling member 1 is set in the interior of the pillar 21,the foaming base material 2 of the foam filling member 1 is introducedin the interior space 24 of the one straight pipe portion 22 from an endthereof on the side of the other short side surface 12 or on the freeend side of the second linearly extending portion 16 of the foam fillingmember 1 through the opening 26 of the pillar 21, first. Then, it isinserted further until the second linearly extending portion 16 reachesa specified location in the interior space 24 of the other straight pipeportion 23, while it is bent along the bend pipe portion 20. As a resultof this, the second linearly extending portion 16 is placed in theinterior space 24 of the other straight pipe portion 23; the firstbending portion 17 is placed in the interior space 24 of the bend pipeportion 20; and the first linearly extending portion 15 is placed in theinterior space 24 of the one straight pipe portion 22, as shown in FIG.5.

Thus, according to this foam filling member 1, the foaming base material2 can be formed in a three-dimensional shape corresponding in shape andsize to the interior space 24 of the pillar 21 formed in the elbow shapewith improved working efficiency by a simple structure of simply bendingthe foaming base material 2 in sheet form along the incisions 4, 5, 6, 7and the cuts 9, 10.

Specifically, the first linearly extending portion 15 and the secondlinearly extending portion 16 of the foaming base material 2 are formedin the inverted U-shape corresponding to radially sectioned shapes ofthe interior spaces 24 of the two straight pipe portions 22, 23 bysimply bending those portions 15, 16 along the incisions 4, 5 formedalong the longitudinal direction of the foaming base material 2 toextend in the widthwise direction of the foaming base material 2.

Also, the first linearly extending portion 15, the second linearlyextending portion 16, and the first bending portion 17 are bent alongthe incisions 6, 7 and cuts 9, 10 formed along the widthwise directionof the foaming base material 2, respectively, in the longitudinaldirection of the foaming base material 2. Further, the first bendingportion 17 is curved to cover the one side surface 3 of the first andsecond linearly extending portions 15, 16 as bent in the invertedU-shape in section and thereby is formed in the inverted U-shape insection corresponding to the radially sectioned shape of the interiorspace 24 of the bend pipe portion 20.

By selecting the locations and the number of incisions 4, 5, 6, 7, andcuts 9, 10 to be formed in the foaming base material 2 or the angles ofthe respective strips of the foaming base material 2 to be bent alongthe incisions 4, 5, 6, 7, and cuts 9, 10 properly for producing the foamfilling member 1, the foam filling member 1 can be formed in anythree-dimensional shapes, such as, for example, the elbow shape asmentioned above, corresponding to various shapes of the pillar 21. Thiscan eliminate the need of the mold having a cavity corresponding to theshape of the interior space 24 of the pillar 21, and the like, and assuch can allow cost reduction.

Also, the foaming base material 2 of the foam filling member 1 isintroduced in the interior space 24 of the one straight pipe portion 22from an end thereof on the side of the other short side surface 12through the opening 26 of the pillar 21, first, and, then, is insertedfurther until the second linearly extending portion 16 reaches aspecified location in the interior space 24 of the other straight pipeportion 23, while it is bent along the bend pipe portion 20. As a resultof this, the foaming base material 2 is placed in the interior space 24of the pillar 21 in the state of its bent portions bent along theincisions 4, 5, 6, 7 and the cuts 9, 10 and outer edges of the foamingbase material 2 being in point-contact with or line-contact with theinside wall defining the interior space 24 of the pillar 21.

Thus, since the foaming base material 2 can be configured to correspondto the shape of the interior space 24, it can be placed in the interiorspace 24 without any need to be stuck on the inside wall of the interiorspace 24, thus producing an improved working efficiency. Also, since thefoaming base material 2 is in the state of being not stuck on the insidewall of the interior space 24, the inside wall can be subjected to arust-proof treatment and the like, as mentioned later, even after theplacement of the foam filling member 1.

In addition, since the foaming base material 2 of the foam fillingmember 1 is formed to have a thickness of 0.5-6.0 mm and a flexuralmodulus of elasticity of 20-150 MPa, a resilience (repellent) to forcethe foaming base material 2 as was placed in the interior space 24 inthe bent state back into its original sheet form before bent isproduced. This resilience of the foaming base material 2 brings the foamfilling member 1 placed in the interior space 24 into press-contact withthe inside wall of the interior space 24, to hold the foam fillingmember 1 in a certain shape in the interior space 24 of the pillar 21.This can produce the result that the foam filling member 1 in theinterior space 24 of the pillar 21 can be reliably held in the formcorresponding to the interior space 24.

Then, after the interior space 24 of the pillar 21 is subjected torequired treatments, such as a rust-proof treatment, the foaming basematerial 2 of the foam filling member 1 is foamed and cured by heating(at a temperature of the order of 120-210° C.) in a subsequent processsuch as, for example, a drying line process at the baking finish, tothereby produce the foam, whereby the interior space 24 of the pillar 21is filled up with the foam, leaving no space therein.

It is preferable that the foam has a density (weight (g) of foam/volume(cm³) of foam) of e.g. 0.04-0.2 g/cm³, or preferably 0.05-0.1 g/cm³.Also, it is preferable that the foaming material is foamed at a foamratio of five to twenty-five times, or preferably ten to twenty times,to obtain the foam.

FIG. 6 is a plane view showing an another embodiment (a ring-shapedtype) of the foam filling material of the present invention, and FIG. 7is an enlarged plane view showing a retaining portion of the foam filingmember of FIG. 6.

A foam filling member 27 shown in FIG. 6 is used for filling foamingmaterial in e.g. an interior space 78 of a pillar 77 of a vehicle asmentioned later and is formed by a single layer of foaming base material28 in sheet form of foamable material (Cf. FIG. 8).

The foaming base material 28 is formed of foaming material which isfoamed by heating (e.g. at about 120° C. to about 210° C.), as is thecase with the above. The foaming base material 28 is formed in arectangular plate-like shape as viewed from top, and comprises a firstmember 29, a second member 30, and a retaining portion 33 providedbetween the first member 29 and the second member 30. The first member29, the second member 30, and the retaining portion 33 are arranged inthe longitudinal direction of the foaming base material 28 atpredetermined spaced intervals and formed in one piece. The first member29 and the second member 30 are aligned with each other with respect tothe longitudinal direction and are joined to each other via theretaining portion 33 so that one short side surface 31 of the firstmember 29 on one longitudinal side thereof and one short side surface 32of the second member 30 on one longitudinal side thereof confront eachother across a predetermined spaced interval.

The first member 29 has incisions 35, 36, 37, 38, 39 formed in a surface34 on one side thereof which are cut in partway along a thicknessdirection thereof and cuts 41, 42 passing completely through to asurface 40 on the other side in the thickness direction. The secondmember 30 has incisions 44, 45, 46, 47, 48, 49, 50 formed in a surface43 on one side thereof which are cut partway along a thickness directionthereof and cuts 52, 53 passing completely through to a surface 51 onthe other side in the thickness direction.

In FIG. 6, in order to make discrimination between the incisions 35-39and 44-50 and the cuts 41, 42, and 52, 53, the incisions 35-39 and 44-50are depicted in a broken line, and the cuts 41, 42, and 52, 53 aredepicted in a solid line, for descriptive purposes.

A plurality of incisions 35 (four incisions) are formed linearly in thesurface 34 on one side of the first member 29 to extend from one shortside surface 31 on one longitudinal side thereof along the longitudinaldirection of the first member 29 to the first cuts 41, 42 from the oneshort side surface 31 which are formed partway along the longitudinaldirection of the first member 29. These incisions 35 are arranged inparallel with each other at predetermined spaced intervals along awidthwise direction which is a direction orthogonal to the longitudinaldirection of the first member 29. These four incisions 35 are equallyspaced along the widthwise direction of the first member 29, to takefive equal parts of the first member 29. The cut-in depth and width ofthe incisions 35 are the same as those of the incisions 4 mentionedabove.

A plurality of incisions 36 (four incisions) are formed linearly in thesurface 34 on one side of the first member 29 to extend from the secondcuts 41, 42 from one short side surface 31 of the first member 29 whichare formed in a substantially lengthwise center portion thereof to thethird cuts 41, 42 from the one short side surface 31 which are formed onthe other side partway along the longitudinal direction of the firstmember 29 along the longitudinal direction of the first member 29. Theseincisions 36 are arranged in parallel with each other at predeterminedspaced intervals along the widthwise direction of the first member 29.These four incisions 36 are equally spaced along the widthwise directionof the first member 29, to take five equal parts of the first member 29.The cut-in depth and width of the incisions 36 are the same as those ofthe incisions 4 mentioned above.

A plurality of cuts (three cuts) 41 are formed linearly in the surface34 on one side of the first member 29 to extend from one long sidesurface 55 on one widthwise side thereof to the second incisions 35, 36from the one long side surface 55 along the widthwise direction of thefirst member 29. The cuts 41 are arranged in parallel with each other atpredetermined spaced intervals in the longitudinal direction of thefirst member 29.

A plurality of cuts (three cuts) 42 are formed linearly in the surface34 on one side of the first member 29 to extend from the other long sidesurface 56 on one widthwise side thereof to the second incisions 35, 36from the other long side surface 56 along the widthwise direction of thefirst member 29. The cuts 42 are arranged in parallel with each other atpredetermined spaced intervals, extending partway along the longitudinaldirection of the first member 29.

The respective cuts 41, 42 are arranged to confront each other acrosspredetermined spaced intervals along the widthwise direction of thefirst member 29 (the spaced intervals defined between the secondincisions 35, 36 from the one long side surface 55 and the secondincisions 35, 36 from the other long side surface 56).

The incisions 37, 38, 39 are formed linearly along the widthwisedirection to connect between the respective cuts 41, 42 arranged inlines to confront each other, respectively. The cut-in depth and widthof the incisions 37, 38, 39 are the same as those of the incisions 4.

As a result of this formation of the incisions 35, 36, 37, 38, 39 andthe cuts 41, 42, a first bending portion 60 is defined by the othershort side surface 54, the incision 39, and the cuts 41, 42 formed atboth widthwise sides of the incision 39; a first linearly extendingportion 61 is defined by the incision 39, the cuts 41, 42 formed at bothwidthwise sides of the incision 39, the incision 38, and the cuts 41, 42formed at both widthwise sides of the incision 38; a second bendingportion 62 is defined by the incision 38, the cuts 41, 42 formed at bothwidthwise sides of the incision 38, the incision 37, and the cuts 41, 42formed at both widthwise sides of the incision 37; and a second linearlyextending portion 63 is defined by the incision 37, the cuts 41, 42formed at both widthwise sides of the incision 37, and the one shortside surface 31. These first bending portion 60, the first linearlyextending portion 61, the second bending portion 62, and the secondlinearly extending portion 63 are arranged in the longitudinal directionof the first member 29.

In the first linearly extending portion 61, a plurality of first bendingstrips 64 (five bending strips) defined by the one long side surface 55,the other long side surface 56, and the respective incisions 36 arearranged along the widthwise direction. In the second linearly extendingportion 63, a plurality of second bending strips 65 (five bendingstrips) defined by the one long side surface 55, the other long sidesurface 56, and the respective incisions 35 are arranged along thewidthwise direction.

The first bending portion 60 and the first linearly extending portion 61are coupled to each other through the incision 39 so that they can bebent in the longitudinal direction of the first member 29. The firstlinearly extending portion 61 and the second bending portion 62 arecoupled to each other through the incision 38 so that they can be bentin the longitudinal direction of the first member 29. Further, thesecond bending portion 62 and the second linearly extending portion 63are coupled to each other through the incision 37 so that they can bebent in the longitudinal direction of the first member 29.

This can allow the first member 29 to be bent along the cut-in directionof the incisions 36, 35 at the first linearly extending portion 61 andthe second linearly extending portion 63, so that the first bendingstrips 64 and the second bending strips 65, adjoining to each other inthe widthwise direction of the first member 29, can be bent atpredetermined angles relative to each other.

This can also allow the first member 29 to be bent along the cut-indirections of the incisions 39, 38, 37 at the boundaries between thefirst bending portion 60 and the first linearly extending portion 61,between the first linearly extending portion 61 and the second bendingportion 62, and between the second bending portion 62 and the secondlinearly extending portion 63, so that the first bending portion 60 andthe first linearly extending portion 61, the first linearly extendingportion 61 and the second bending portion 62, and the second bendingportion 62 and the second linearly extending portion 63, adjoining toeach other in the longitudinal direction of the first member 29, arebent at predetermined angles relative to each other, respectively.

A plurality of incisions 44 (four incisions) are formed linearly in thesurface 43 on one side of the second member 30 to extend from the oneshort side surface 32 along the longitudinal direction of the secondmember 30 to the first cuts 52, 53 from the one short side surface 31which are formed partway along the longitudinal direction of the secondmember 30. These incisions 44 are arranged in parallel with each otherat predetermined spaced intervals along a widthwise direction which is adirection orthogonal to the longitudinal direction of the second member30. These four incisions 44 are equally spaced along the widthwisedirection of the second member 30, to take five equal parts of thesecond member 30. The cut-in depth and width of the incisions 44 are thesame as those of the incisions 4 mentioned above.

A plurality of incisions 45 (four incisions) are formed linearly in thesurface 43 on one side of the second member 30 to extend from the secondcuts 52, 53 from one short side surface 32 of the second member 30 whichare formed partway along the longitudinal direction of the second member30 to the third cuts 52, 53 from the one short side surface 32 which areformed on the other side partway along the longitudinal direction of thesecond member 30 along the longitudinal direction of the second member30. These incisions 45 are arranged in parallel with each other atpredetermined spaced intervals along the widthwise direction of thesecond member 30. These four incisions 45 are equally spaced along thewidthwise direction of the second member 30, to take five equal parts ofthe second member 30. The cut-in depth and width of the incisions 45 arethe same as those of the incisions 4 mentioned above.

A plurality of incisions 46 (four incisions) are formed linearly in thesurface 43 on one side of the second member 30 to extend from the othershort side surface 57 located on the other longitudinal side of thesecond member 30 to the forth cuts 52, 53 from the one short sidesurface 32 which are formed on the other side partway along thelongitudinal direction of the second member 30 along the longitudinaldirection of the second member 30. These incisions 46 are arranged inparallel with each other at predetermined spaced intervals along thewidthwise direction of the second member 30. These four incisions 46 areequally spaced along the widthwise direction of the second member 30, totake five equal parts of the second member 30. The cut-in depth andwidth of the incisions 46 are the same as those of the incisions 4mentioned above.

A plurality of cuts (four cuts) 52 are formed linearly in the surface 43on one side of the second member 30 to extend from one long side surface58 on one widthwise side thereof to the second incisions 44, 45, 46 fromthe one long side surface 58 along the widthwise direction of the secondmember 30. The cuts 52 are arranged in parallel with each other atpredetermined spaced intervals in the longitudinal direction of thesecond member 30.

A plurality of cuts (four cuts) 53 are formed linearly in the surface 43on one side of the second member 30 to extend from the other long sidesurface 59 on the other widthwise side thereof to the second incisions44, 45, 46 from the other long side surface 59 along the widthwisedirection of the second member 30. The cuts 53 are arranged in parallelwith each other at predetermined spaced intervals along the longitudinaldirection of the second member 30. The respective cuts 52, 53 arearranged to confront each other across predetermined spaced intervalsalong the widthwise direction of the second member 30 (the spacedintervals defined between the second incisions 44, 45, 46 from the onelong side surface 58 and the second incisions 44, 45, 46 from the otherlong side surface 59).

The incisions 47, 48, 49, 50 are formed linearly along the widthwisedirection to connect between the respective cuts 52, 53 arranged inlines to confront each other, respectively. The cut-in depth and widthof the incisions 47, 48, 49, 50 are the same as those of the incisions4.

As a result of this formation of the incisions 44, 45, 46, 47, 48, 49,50 and the cuts 52, 53, a third linearly extending portion 66 is definedby the other short side surface 32, the incision 47, and the cuts 52, 53formed at both widthwise sides of the incision 47; a third bendingportion 67 is defined by the incision 47 and the cuts 52, 53 formed atboth widthwise sides of the incision 47, the incision 48, and the cuts52, 53 formed at both widthwise sides of the incision 48; a fourthlinearly extending portion 68 is defined by the incision 48, the cuts52, 53 formed at both widthwise sides of the incision 48, the incision49, and the cuts 52, 53 formed at both widthwise sides of the incision49; a fourth bending portion 69 is defined by the incision 49, the cuts52, 53 formed at both widthwise sides of the incision 49, the incision50, and the cuts 52, 53 formed at both widthwise sides of the incision50, and a fifth linearly extending portion 70 is defined by the incision50, the cuts 52, 53 formed at both widthwise sides of the incision 50,and the one short side surface 57. These third linearly extendingportion 66, the third bending portion 67, the fourth linearly extendingportion 68, the fourth bending portion 69, and the fifth linearlyextending portion 70 are arranged in the longitudinal direction of thesecond member 30.

In the third linearly extending portion 66, a plurality of third bendingstrips 71 (five bending strips) defined by the one long side surface 58,the other long side surface 59, and the respective incisions 44 arearranged along the widthwise direction. In the fourth linearly extendingportion 68, a plurality of fourth bending strips 72 (five bendingstrips) defined by the one long side surface 58, the other long sidesurface 59, and the respective incisions 45 are arranged along thewidthwise direction. Further, in the fifth linearly extending portion70, a plurality of fifth bending strips 73 (five bending strips) definedby the one long side surface 58, the other long side surface 59, and therespective incisions 46 are arranged along the widthwise direction.

The third linearly extending portion 66 and the third bending portion 67are coupled to each other through the incision 47 so that they can bebent in the longitudinal direction of the second member 30. The thirdbending portion 67 and the fourth linearly extending portion 68 arecoupled to each other through the incision 48 so that they can be bentin the longitudinal direction of the second member 30. The fourthlinearly extending portion 68 and the fourth bending portion 69 arecoupled to each other through the incision 49 so that they can be bentin the longitudinal direction of the second member 30. Further, thefourth bending portion 69 and the fifth linearly extending portion 70are coupled to each other through the incision 50 so that they can bebent in the longitudinal direction of the second member 30.

This can allow the second member 30 to be bent along the cut-indirection of the incisions 44, 45, 46 at the third linearly extendingportion 66, the fourth linearly extending portion 68, and the fifthlinearly extending portion 70, so that the third bending strips 71, thefourth bending strips 72, and the fifth bending strips 73, adjoining toeach other in the widthwise direction of the second member 30, can bebent at predetermined angles relative to each other.

This can also allow the second member 30 to be bent along the cut-indirections of the incisions 47, 48, 49, 50 at the boundaries between thethird linearly extending portion 66 and the third bending portion 67,between the third bending portion 67 and the fourth linearly extendingportion 68, between the fourth linearly extending portion 68 and thefourth bending portion 69, and between the fourth bending portion 69 andthe fifth linearly extending portion 70, so that the third linearlyextending portion 66 and the third bending portion 67, the third bendingportion 67 and the fourth linearly extending portion 68, the fourthlinearly extending portion 68 and the fourth bending portion 69, and thefourth bending portion 69 and the fifth linearly extending portion 70,adjoining to each other in the longitudinal direction of the secondmember 30, are bent at predetermined angles relative to each other,respectively.

The retaining portion 33 comprises a connecting portion 74 of arectangular plate-like form, when viewed from top, for connectingbetween the second linearly extending portion 63 of the first member 29and the third linearly extending portion 66 of the second member 30, apair of retaining arms 75 projecting from a lengthwise center of theconnecting portion 74 toward both widthwise sides thereof, andprotruding portions 76 projecting from a lengthwise center of theconnecting portion 74 toward both widthwise sides thereof. Theconnecting portion 74, the pair of retaining arms 75, and the protrudingportions 76 are formed in one piece (Cf. FIG. 7)

The connecting portion 74 connects between a center portion of the oneshort side surface 31 of the first member 29 and a center portion of theone short side surface 32 of the second member 30. The connectingportion 74 has a width C formed to be equal to the widths of the secondbending strips 65 and the third bending strips 71. It is formed toextend continuously with the second bending strip 65 located at thewidthwise center of the second linearly extending portion 63 and thethird bending strip 71 located at the widthwise center of the thirdlinearly extending portion 66.

The retaining arms 75 are formed in a rectangular plate-like shape, asviewed from top, extending in a direction orthogonal to the longitudinaldirection of the connecting portion 74.

The protruding portions 76 are formed in a generally triangularplate-like shape, obliquely extending at sides thereof extendingcontinuously with the retaining arms 75. The connecting portion 74 isformed to have free ends extending beyond the top of the protrudingportions 76 in the widthwise direction of the retaining arms 75.

The foaming base material 28 is continuously formed in sheet form in thesame manner as in the above. Then, the resulting sheet is stamped sothat it can be formed in a predetermined shape having the first member29, the second member 30 and the retaining portion 33, and also theincisions 35-39 and the cuts 41, 42 can be formed in the surface 34 ofthe first member 29 on one side thereof and the incisions 44-50 and thecuts 52, 53 can be formed in the surface 43 of the second member 30 onone side thereof.

The foaming base material 28 thus produced is bent along the incisions35-39, and 44-50 in the direction orthogonal to the cut-in direction ofthe incisions, with the one side surfaces 34, 43 outward, and the otherside surfaces 40, 51 inward with respect to the bending direction. As aresult, the foaming base material 28 is formed in a generally circularform shown in FIG. 8, as viewed from side elevation.

Specifically, the five first bending strips 64 of the first linearlyextending portion 61 are bent along the four incisions 36 connectingbetween the first bending strips 64 in the direction orthogonal to thecut-in direction of the incisions, with the one side surface 34 outward,and the other side surface 40 inward with respect to the bendingdirection, to thereby form the foaming base material 28 having aninverted U-shaped section as viewed from the widthwise directionthereof.

The five second bending strips 65 of the second linearly extendingportion 63 are bent along the four incisions 35 connecting between thesecond bending strips 65 in the direction orthogonal to the cut-indirection of the incisions, with the one side surface 34 outward, andthe other side surface 40 inward with respect to the bending direction,to thereby form the foaming base material 28 having an inverted U-shapedsection as viewed from the widthwise direction thereof, as in the caseof the above.

The five third bending strips 71 of the third linearly extending portion66 are bent along the four incisions 44 connecting between the thirdbending strips 71 in the direction orthogonal to the cut-in direction ofthe incisions, with the one side surface 43 outward, and the other sidesurface 51 inward with respect to the bending direction, to thereby formthe foaming base material 28 having an inverted U-shaped section asviewed from the widthwise direction thereof, as in the case of theabove.

The five fourth bending strips 72 of the fourth linearly extendingportion 68 are bent along the four incisions 45 connecting between thefourth bending strips 72 in the direction orthogonal to the cut-indirection of the incisions, with the one side surface 43 outward, andthe other side surface 51 inward with respect to the bending direction,to thereby form the foaming base material 28 having an inverted U-shapedsection as viewed from the widthwise direction thereof, as in the caseof the above.

The five fifth bending strips 73 of the fifth linearly extending portion70 are bent along the four incisions 46 connecting between the fifthbending strips 73 in the direction orthogonal to the cut-in direction ofthe incisions, with the one side surface 43 outward, and the other sidesurface 51 inward with respect to the bending direction, to thereby formthe foaming base material 28 having an inverted U-shaped section asviewed from the widthwise direction thereof.

Also, the respective bending portions and the respective linearlyextending portions are bend along their respective incisions 37-39 and47-50 connecting therebetween, in the direction orthogonal to the cut-indirections of the incisions. In addition, the first bending portion 60and the second bending portion 62, and the third bending portion 67 andthe fourth bending portion 69 are curved to cover the one side surface34 of the first linearly extending portion 61 and the second linearlyextending portion 63, and the one side surface 43 of the third linearlyextending portion 66, the fourth linearly extending portion 68, and thefifth linearly extending portion 70, as were bend in the invertedU-shape in section, respectively. As a result, the foam filling member28 is formed in an annular form, as viewed from side elevation, with theone side surfaces 34, 43 outward, and the other side surfaces 40, 51inward with respect to the bending direction.

Further, the retaining portion 33 is folded in two in the same directionat a lengthwise center of the connecting portion 74 and also baseportions of the connecting portion 74 are bent outwardly of the annulus,as shown in FIGS. 8 and 9, and, further, the retaining arms 75 are bentinwardly of the annulus to project outwardly of the annulus, as shown inFIG. 10.

Then, after the foam filling member 27 thus produced is placed in thespace of the structure or the interior space of the hollow structure, itis heated to a foaming temperature. Then, the foam filling member 27 isfoamed to fill up the space of the structure, leaving no space therein.Accordingly, this foam filling member 27 can be applied as variousindustrial products.

Next, a method of filling up the interior space of the pillar of thevehicle will be explained, taking an example of use of this foam fillingmember 27.

In this method, the foam filling member 27 formed to correspond in shapeand size to a three-dimensional configuration of the interior space 78of the pillar 77 to be filled is set in the pillar 77, first, as shownin FIG. 8.

The pillar 77 comprises an inner panel 79 and an outer panel 80. Each ofthe inner panel 79 and the outer panel 80 has a concave shape of crosssection having an opening at one side thereof and has a flange 81, 82,formed at both ends, to extend along an opening width of the opening.The inner panel 79 and the outer panel 80 are welded together, withtheir flanges 81, 82 abutted with each other, whereby the pillar 77 isformed to define the interior space 78 as a closed section.

When the foam filling member 27 is placed in the interior of the pillar77, the inner panel 79 and the outer panel 80 of the pillar 77 are inthe state of being separated from each other. Then, the foam fillingmember 27 is bent along the respective incisions 35-39, and 44-50 in thedirection orthogonal to the cut-in direction of the incisions, with theone side surface 34, 43 outward and the other side surface 40, 51 inwardwith respect to the bending direction, so that it is formed in agenerally annular shape corresponding to the shape of cross section ofthe pillar 77, when viewed from side elevation. Then, the retainingportion 33 is retained in a retaining hole 83 previously formed in theinner panel 79.

Specifically, the retaining arms 75 and protruding portions 76 of theretaining portion 33 are inserted through the retaining hole 83 asindicated by a solid arrow of FIG. 9. The retaining hole 83 is formed sothat a width E (FIG. 10) of the pillar 77 extending along a longitudinaldirection thereof is larger than a width C of the connecting portion 74and also smaller than a width D (FIG. 7) between apexes of theprotruding portions 76 protruding from both sides of the connectingportion 74. This configuration can allow the passage of the retainingarms 75 and the protruding portions 76 through the retaining hole 83,while being elastically deformed inwardly in the widthwise directionand, after the passage through the retaining hole 83, allows theresilient deformation of the same outwardly in the widthwise directionto put the free ends of the retaining arms 75 and the end portions ofthe protruding portions 76 into abutment with an outside surface of theinner panel 79, as shown in FIG. 10. As a result, the foam fillingmember 27 is fixed to the inner panel 79.

Thereafter, the flanges 81, 82 of the inner panel 79 and the outer panel80 are abutted with each other and then welded together, so that thefoam filling member 27 is set in place in the pillar 77.

This pillar 77 is used specifically as a front pillar, a side pillar, ora rear pillar of a vehicle body.

Then, after the pillar 77 is subjected to required treatments, such as arust-proof treatment, the foaming base material 28 of the foam fillingmember 27 is foamed and cured by heating in a subsequent process suchas, for example, a drying line process at the baking finish, to therebyproduce the foam, whereby the interior space 78 of the pillar 77 isfilled up with the foam, leaving no space therein. It is preferable thatthe foam obtained has substantially the same density and foam ratio asthose of the above.

In the foam filling member 27, the foam filling member 27 can be fixedto the pillar 77 by retaining the retaining portion 33 in the retaininghole 83 of the pillar 77. This can allow the foam filling member 27 tobe fixed to the inside surface defining the interior space 28 at theretaining portion 33 only, and as such can ensure the fixture of thefoam filling member 27 to the pillar 77, without negatively affectingsubsequent treatments to the wall of the interior space, such as therust-proof treatment.

FIG. 11 is a plane view showing still another embodiment of the foamfilling member of the present invention.

A foam filling member 84 shown in FIG. 11 is used for filling foamingmaterial in a first space 100 and a second space 101 of a pillar 99 of avehicle comprising the adjoining first and second spaces 100 and 101mentioned later and is formed by a single layer of foaming base material85 in sheet form of foamable material (Cf. FIG. 12).

The foaming base material 85 is formed of foaming material which isfoamed by heating (e.g. at about 120° C. to about 210° C.) as in thecase of above. The foaming base material 85 is formed in a rectangularshape, as viewed from top, comprising an inserting portion 90 formedpartway along a longitudinal direction thereof, a first space fillingportion 92 formed at one lengthwise side thereof with respect to theinserting portion 90, and a second space filling portion 94 formed atthe other lengthwise side thereof with respect to the inserting portion90. The respective portions 90, 92, and 94 are formed in one piece.

Specifically, the foaming base material 85 has a generally V-shapedrecess 87, as viewed from top, which is formed partway along thelengthwise dimension of its one long side surface 86 on the widthwiseone side of the foaming base material 85, to be recessed inwardly in awidthwise direction which is a direction orthogonal to the longitudinaldirection. It also has a generally V-shaped recess 89, as viewed fromtop, which is formed partway along the lengthwise dimension of the otherlong side surface 88 on the widthwise opposite side of the foaming basematerial 85, to be recessed inwardly in the widthwise direction. Therecess 87 and the recess 89 are formed at locations confronting eachother with respect to the widthwise direction of the foaming basematerial 85.

Thus, the foaming base material 85 has the narrowest portion in agenerally rectangular shape in the form of the inserting portion 90which is defined by the recesses 87, 89 formed to confront each other inthe widthwise direction of the foaming base material 85 at locations inthe longitudinal direction of the foaming base material 85. It also has,at both sides of the inserting portion 90, the first space fillingportion 92 which is defined by a generally rectangular portion of thefoaming base material extending from one lateral side thereof to oneshort side surface 91, and the second space filling portion 94 which isdefined by a generally rectangular portion of the foaming base materialextending from the other lateral side thereof to the other short sidesurface 93.

The first space filling portion 92 and the second space filling portion94 are formed to have the same width F, and the inserting portion 90 isformed to have a width G narrower than the width F.

The foaming base material 85 has incisions 96 formed in a surface 95 onone side thereof which are cut partway along a thickness directionthereof and also has incisions 98 formed in a surface 97 on the otherside thereof which are cut partway along the thickness directionthereof. In FIG. 11, in order to make discrimination between theincisions 96 formed in the surface 95 on the one side and the incisions98 formed in the surface 97 on the other side opposite to the one side,the incisions 96 are depicted in a solid line, and the incisions 98 aredepicted in a broken line, for descriptive purposes.

The incisions 96 are formed in an area of the one side surface 95 of thefoaming base material 85 located near the one short. side surface 91 onone lengthwise side of the first space filling portion 92 and in asubstantially lengthwise center area of the same, two or more for eacharea, extending linearly along the widthwise direction of the foamingbase material 85.

The incisions 98 are formed in an area of the other side surface 93 ofthe foaming base material 85 located near the other short side surface96 on the other lengthwise side of the second space filling portion 94and in an area located near the inserting portion 90 including theinserting portion 90, two or more for each area, extending linearlyalong the widthwise direction of the foaming base material 85.

Although the example wherein six incisions 96 and seven incisions 96 areformed in the area near the one short side surface 95 and in thesubstantially lengthwise center area, respectively, and five incisions94 and six incisions 94 are formed in the area near the other short sidesurface 98 and in the area near the inserting portion 90, respectively,has been illustrated in FIG. 11, the real number of incisions are notlimited thereto.

The foaming base material 85 is continuously formed in sheet form in thesame manner as in the above. Then, the resulting sheet is stamped sothat it can be formed in the generally rectangular shape having thefirst space filling portion 92, the inserting portion 90, and the secondspace filling portion 94, and also the incisions 96 can be formed in thesurface 91 on one side thereof and the incisions 98 can be formed in thesurface 93 on the other side thereof.

The foaming base material 85 thus produced is bent along the incisions96 in the direction orthogonal to the cut-in direction of the incisions,with the one side surface 91 outward, and the other side surface 93inward with respect to the bending direction and also is bent along theincisions 98 in the direction orthogonal to the cut-in direction of theincisions, with the other side surface 93 outward, and the one sidesurface 91 inward with respect to the bending direction. As a result,the foaming base material 85 is formed in a generally figure-eight shapeas viewed from side elevation as shown in FIG. 12.

The foam filling member 84 thus produced is placed in a space betweenstructures or in an interior space of a hollow structure and then isheated to a foaming temperature. Then, the foam filling member 84 isfoamed and thereby the space is filled up, without leaving any spacetherein. Therefore, this foam filling member 84 can be used as foamfilling members of a variety of industrial products.

Next, a method of filling up adjoining the first and second spaces ofthe pillar of the vehicle will be explained, taking an example of use ofthis foam filling member 84.

In this method, the foam filling member 84 formed to correspond in shapeand size to a three-dimensional configuration of the adjoining the firstspace 100 and the second space 101 of the pillar 99 to be filled is setin the pillar 99, first, as shown in FIG. 12.

The pillar 99 comprises an inner panel 102, an outer panel 103 and acenter panel 104. Each of the inner panel 102 and the outer panel 103has a generally concave shape of cross section having an opening at oneside thereof and has a flange 105, 106, formed at both ends, to extendalong an opening width of the opening. The center panel 104 has agenerally concave shape of cross section to be fitted in the opening ofthe outer panel 103 and having a flange 107 formed at both ends, toextend along the opening width of the opening. It has a communicatinghole 108, formed in a recessed portion thereof, to extend through in thethickness direction. The communicating hole 108 has a width extendingalong the longitudinal direction of the pillar 99, the width being lagerthan the width G of the communicating portion 90 but smaller than thewidth F of the first and second space filling portions 92 and 94.

The pillar 99 is formed so that the inner panel 102, the center panel104, and the outer panel 103 are welded together with their flanges 105,106, and 107 abutted with each other in the state of the center panel104 being sandwiched between the inner panel 102 and the outer panel 103and thereby the first space 100 is defined as the closed section betweenthe inner panel 102 and the center panel 104, and the second space 101is defined as the closed section between the outer panel 103 and thecenter panel 104.

When the foam filling member 84 is placed in the interior of the pillar99, the inner panel 102, the center panel 104, and the outer panel 103of the pillar 99 are in the state of being separated from each other. Inthis state, the second space filling portion 94 of the foam fillingmember 84 is inserted in the communicating hole 108 of the center panel104, while being bent the second space filling portion 94 of the foamfilling member 84 in the widthwise direction and, then, the insertingportion 90 is inserted in and passes through the communicating hole 108.

Thereafter, in the state of the first space filling portion 92 of thefoam filling member 84 being bent along the incisions 96 so that it canextend along the shape of the cross-section of the inside surface of theinner panel 102 (the first space 100) to be bent along the longitudinaldirection thereof and also the second space filling portion 94 of thefoam filling member 84 being bent along the incisions 98 so that it canextend along the shape of the cross-section of the inside surface of theouter panel 103 (the second space 101) to be bent along the longitudinaldirection thereof, the inner panel 102, the outer panel 103, and thecenter panel 104 are welded together with their flanges 105, 106, and107 abutted with each other. The foam filling member 84 is placed in theinterior of the pillar 99 in this manner. This pillar 99 is usedspecifically as the front pillar, the side pillar, or the rear pillar ofa vehicle body.

Then, after the pillar 99 is subjected to required treatments, such asthe rust-proof treatment, the foaming base material 85 of the foamfilling member 84 is foamed and cured by heating in the subsequentprocess such as, for example, the drying line process at the bakingfinish, to thereby produce the foam, whereby the first space 100 and thesecond space 101 of the pillar 99 are filled up with the foam, leavingno space therein. It is preferable that the foam obtained hassubstantially the same density and foam ratio as those of the above.

The foam filling member 84 thus configured can allow the placement ofthe first space filling portion 92 in the first space 100 and theplacement of the second space filling portion 94 in the second space 101by simply inserting the inserting portion 90 through the communicatinghole 108. Thus, the need to place the space filling member in each ofthe first space 100 and the second space 101, one for each, can beeliminated, thus providing an improved working efficiency. Also, sinceonly a single space filling member is required for filling both spaces100, 101, cost reduction can also be achieved.

FIG. 13 is a plane view showing a yet another embodiment of the foamfilling member of the present invention.

In FIG. 13, this foam filling member 109, which is used for filling foamin an interior space 125 of a vehicle pillar 124, as mentioned later,comprises a first foaming base material 110 and a second foaming basematerial 111 which are of foamable material in sheet form and separatefrom each other (Cf. FIG. 14).

The first foaming base material 110 and the second foaming base material111 are formed of foaming material which is foamed by heating (e.g. atabout 120° C. to about 210° C.), as is the case in the above. The bothfoaming base materials 110, 111 are formed in a rectangular shape, asviewed from top.

The first foaming base material 110 has cutouts 113, formed at certainlengthwise locations in a surface 112 on one long side thereof or in onewidthwise side surface thereof, to extend through in the thicknessdirection and allow insertion of the second foaming base material 111.The cutouts 113 are formed in the one long side surface 112 of the firstfoaming base material 110 at a lengthwise location near one short sidesurface 114 which is a side surface on one lengthwise side of thesurface 112 and at a lengthwise location near the other short sidesurface 115 which is a side surface on the other lengthwise side of thesurface 112, respectively, so that they are spaced apart from each otherat a predetermined interval in the longitudinal direction of the firstfoaming base material 110. The cutouts 113 are cut out in concave formfrom the one long side surface 112 toward the other long side surface120 which is a side surface on the other widthwise side of the firstfoaming base material 110. The cutouts 113 are formed in a generallyrectangular form, as viewed from top, with their lengthwise directionscorresponding to the widthwise direction of the first foaming basematerial 110.

Each of the cutouts 113 is formed to have a width H, extending in adirection orthogonal to the longitudinal direction, which is slightlysmaller than a thickness I of the second foaming base material 111inserted. This can allow the second foaming base material 111 insertedto be held in sandwich relation between both side surfaces of the eachcutout 113.

The second foaming base material 111 has cutouts 117, formed at certainlengthwise locations in a surface 116 on one long side thereof or in onewidthwise side surface thereof, to extend through in the thicknessdirection and allow insertion of the first foaming base material 110.The cutouts 117 are formed in one long side surface 116 of the secondfoaming base material 111 at a lengthwise location near one short sidesurface 118 which is a side surface on one lengthwise side of thesurface 116 and at a lengthwise location near the other short sidesurface 119 which is a side surface on the other lengthwise side of thesurface 116, respectively, so that they are spaced apart from each otherat a predetermined interval in the longitudinal direction of the secondfoaming base material 111. The cutouts 117 are cut out in concave formfrom the one long side surface 116 toward the other long side surface122 which is a side surface on the other widthwise side of the secondfoaming base material 111. The cutouts 117 are formed in a generallyrectangular form, as viewed from top, with their lengthwise directionscorresponding to the widthwise direction of the second foaming basematerial 111. Each of the cutouts 117 is formed to have a width J,extending in a direction orthogonal to the longitudinal direction, whichis slightly smaller than a thickness K of the first foaming basematerial 110 inserted. This can allow the first foaming base material110 inserted to be held in sandwich relation between both side surfacesof the each cutout 117.

The first foaming base material 110 and the second foaming base material111 are formed so that the second foaming base material 111 has a largerlongitudinal dimension than the first foaming base material 110 and thespaced interval between the two cutouts 117 of the second foaming basematerial 111 is larger than the spaced interval between the two cutouts113 of the first foaming base material 110. This configuration can allowthe second foaming base materials 111 to be combined with the firstfoaming base material 110 by curving the second foaming base material111 at its lengthwise center portion to be formed into a U-shape asviewed from side elevation, as shown in FIG. 13.

Specifically, the first foaming base material 110 and the second foamingbase material 111 are orthogonally oriented so that an opening of thecutouts 113 of the first foaming base material 110 and an opening of thecutouts 117 of the second foaming base material 111 can confront eachother. Then, coupling portions 121 of the first foaming base material110 extending between the cutouts 113 of the first foaming base material110 and the other long side surface 120 thereof are put in engagement inthe cutouts 117 of the second foaming base material 111 and alsocoupling portions 123 of the second foaming base material 111 extendingbetween the cutouts 117 of the second foaming base material 111 and theother long side surface 122 thereof are put in engagement in the cutouts113 of the first foaming base material 110.

The both foaming base materials 110, 111 are integrally combined witheach other in this manner. The coupling portions 123 of the secondfoaming base material 111 inserted are sandwiched between the both sidesurfaces of the cutouts 113 and also the coupling portions 121 of thefirst foaming base material 110 inserted are sandwiched between the bothside surfaces of the cutouts 117, whereby the both foaming basematerials 110, 111 are fixed to each other. This produces the foamfilling member 109 of the three-dimensional configuration shown in FIG.14.

The foam filling member 109 thus produced is placed in a space betweenstructures or in an interior space of a hollow structure and then isheated to a foaming temperature. Then, the foam filling member 109 isfoamed and thereby the space is filled up, without leaving any spacetherein. Therefore, this foam filling member 109 can be used as foamfilling members of a variety of industrial products.

Next, a method of filling up the interior space of the pillar of thevehicle will be explained, taking an example of use of this foam fillingmember 109.

In this method, the foam filling member 109 formed to correspond inshape and size to a three-dimensional configuration of the interiorspace 125 of the pillar 124 to be filled is set in the pillar 124,first, as shown in FIG. 14.

The pillar 124 comprises an inner panel 126 and an outer panel 127. Theinner panel 126 has a generally concave shape of cross section having anopening at one side thereof and has a flange 128, formed at both endsthereof, to extend along an opening width of the opening. The outerpanel 127 has a generally half-round shape of cross section having anopening at one side thereof and has a flange 129, formed at both endsthereof, to extend along an opening width of the opening. The pillar 124is formed so that the inner panel 126 and the outer panel 127 are weldedtogether with their flanges 128 and 129 abutted with each other andthereby the interior space 125 is defined as the closed section betweenthe inner panel 126 and the outer panel 127.

When the foam filling member 109 is placed in the interior of the pillar124, the inner panel 126 and the outer panel 127 of the pillar 124 arein the state of being separated from each other. In this state, thesecond foaming base material 111 of the foam filling member 109 ascurved is inserted in the outer panel 127. Then, the inner panel 126 islaid over the outer panel 127 to cover the first foaming base material110. Thereafter, the inner panel 126 and the outer panel 127 are weldedtogether with their flanges 128 and 129 abutted with each other. Thefoam filling member 109 is placed in the interior of the pillar 124 inthis manner.

In the pillar 124 thus assembled, the one short side surface 114 and theother short side surface 115 of the first foaming base material 110 andboth lengthwise end portions of the surface 130 on one side of the firstfoaming base material 110 are in contact with receiving surfaces 131 ofthe outer panel 127 formed near the openings, respectively, and the oneshort side surface 118 and the other short side surface 119 of thesecond foaming base material 111 are in contact with an inside surfaceof the inner panel 126, whereby the foam filling member 109 is fixed inthe interior of the pillar 124. This pillar 124 is used specifically asthe front pillar, the side pillar, or the rear pillar of the vehiclebody.

Then, after the pillar 124 is subjected to required treatments, such asthe rust-proof treatment, the first foaming base material 110 and thesecond foaming base material 111 of the foam filling member 109 arefoamed and cured by heating in the subsequent process such as, forexample, the drying line process at the baking finish, to therebyproduce the foam, whereby the interior space 125 of the pillar 124 isfilled up with the foam, leaving no space therein. It is preferable thatthe foam obtained has substantially the same density and foam ratio asthose of the above.

In the foam filling member 109, the foam filling member 109 can beformed in a predetermined shape corresponding to the interior space 125of the pillar 124 by combining the first foaming base material 110 andthe second foaming base material 111 with improved working efficiency byusing a simple structure of simply inserting the second foaming basematerial 111 in the cutouts 113 of the first foaming base material 110in sheet form and inserting the first foaming base material 110 in thecutouts 117 of the second foaming base material 111. This can eliminatethe need of the mold having a cavity corresponding to the shape of theinterior space 125 of the pillar 124, and as such can allow costreduction.

Also, this can allow the foam filling member 109 to be placed in theinterior space 125 of the pillar 124 in the form corresponding to theshape of the interior space 125, without any need to be stuck on theinside walls of the first and second foaming base materials 110 and 111,thus producing an improved working efficiency. Also, since the firstfoaming base material 110 and the second foaming base material 111 arein the state of being not stuck on the inside walls of the interiorspace, the inside walls of the interior space can be subjected to therust-proof treatment and the like even after the placement of the foamfilling member 109.

In the foam filling member of the present invention, the shape, thenumber, and the orientation of the incisions, cuts, and cutouts, and theshape of the foam filling member subjected to these conditions may beselected in accordance with the space of the structure, without beinglimited to those illustrated above.

While the illustrative embodiments of the present invention are providedin the above description, such is for illustrative purpose only and itis not to be construed restrictively. Modification and variation of thepresent invention that will be obvious to those skilled in the art is tobe covered by the following claims.

1-6. (canceled)
 7. A foam filling member used for filling a space of astructure by foaming the structure, the foam filling member comprising:a first foaming base material in a form of a sheet of foamable materialin which cutout portions are cut in a thickness direction thereof,wherein the foam filling member is formed in a predetermined shape byinserting a second foaming base material into the cutout portions. 8.The foam filling member according to claim 7, wherein said first foamingbase material is substantially rectangular in shape and having two longside surfaces, said cutout portions being disposed at distal ends ofsaid first foaming base material, and extending partially from one longside surface of said first foaming base material to said other long sidesurface of said first foaming base material; wherein said second foamingbase material is substantially U-shaped and includes cutout portionsdisposed at distal ends of said second foaming base material, andextending partially from one long side surface of said second foamingbase material to said other long side surface of said second foamingbase material; and wherein said cutout portions of said first foamingbase material and said second foaming base material are coupled togetherto affix the first foaming base material to said second foaming basematerial.